Flexible pallet

ABSTRACT

A flexible pallet manufactured by using plastic woven cloth or sheet, wherein square upper and lower surface materials ( 3 ) and ( 4 ) formed with plastic sheet are seamed to each other so as to form fork pockets ( 5 ) therebetween, and inner surface materials ( 6 ) and ( 7 ) are formed with woven cloth using PP mono-filaments are installed on the inner surface of the fork pockets ( 5 ).

TECHNICAL FIELD

[0001] This invention concerns a flexible pallet manufactured by using, for example, a woven-fabric or a sheet made of plastics and, more in particular, it relates to a flexible pallet with easy insertion of forks and with no worry of detachment even if forks are inclined somewhat.

BACKGROUND ART

[0002] Heretofore, wooden pallets manufactured by using wooden materials have been generally known. However, when wooden pallets are used for exporting cargoes, a fuming treatment is sometimes required for the wooden materials depending on the destinated countries (for example, Australia or New Zealand), to result in a problem that the transportation cost is increased by so much and the effective period for the fuming treatment is as short as about one month to impose restriction in view of time.

[0003] Then pallets made of paper manufactured by using paper materials such as corrugated boards have been proposed and the present applicant has also proposed paper pallets of this kind, for example, in Japanese patent application No. 115690/1998.

[0004] The paper pallet proposed previously by the present applicant has various advantages that large strength can be obtained only by using the paper materials and it has no requirement for reinforcing with a hard plate such as a plywood or chip board. However, since the pallet cannot be folded into a reduced volume, it involves a problem of being bulky during transportation or storage and easily deformed even by a small external force when it is moistened.

[0005] By the way, a pallet is usually used being mounted to two forks of a forklift and the weight of most of cargoes is supported on the two forks of the forklift except for the special cargo that the bottom of a cargo placed on the pallet is easily deformed under the load. Therefore, it is expected that the pallet itself may not be necessarily rigid so long as it has a structure capable of inserting and removing two forks of the forklift and a pallet even of a flexible structure may be used effectively.

[0006] Further, in the existent pallets, they naturally have a height of a predetermined level or more both in wood pallets or paper pallets since they have a structure of insuring the space of fork pockets. It is expected that the loading efficiency of the container transportation can be improved if the height described above can be reduced. Particularly, since pallets are used in one-way manner in most cases and not used repeatedly, if the loading efficiency can be improved, it will be extremely advantageous in view of the transportation cost.

[0007] This invention has been accomplished based on such a concept and it is an object thereof to provide a flexible pallet which can be manufactured easily and produced at a reduced cost, as well as can be folded small during transportation or storage and can reduce the amount of wastes to be discarded after use.

[0008] Another object of this invention is to provide a flexible pallet in which forks of a forklift can be inserted easily into fork pockets even in a case where it is applied as a pallet for cargoes at a second or higher stage loaded on cargoes.

[0009] Other object of this invention is to provide a flexible pallet in which forks of a forklift can be inserted smoothly into fork pockets even when elongate reinforcing members are disposed.

[0010] A further object of this invention is to provide a flexible pallet capable of inserting forks of a forklift smoothly into fork pockets even in a case where heavy weight cargoes with no flat bottom are loaded on a pallet main body.

[0011] A further object of this invention to provide a flexible pallet capable of easily recognizing the positions for fork pockets visually even when the pallet situates between upper and lower cargoes.

[0012] A further object of this invention is to provide a flexible pallet capable of always keeping the end of the fork pocket open on the insertion side.

[0013] A further object of this invention is to provide a flexible pallet in which the end of the open fork pocket on the insertion side is not closed even in a case where a heavy weight load is located on a pallet main body.

[0014] A further object of this invention is to provide a flexible pallet capable of easily inserting forks of a forklift into fork pockets even in a case where the pallet situates between upper and lower cargoes.

[0015] A further object of this invention is to provide a flexible pallet capable of keeping the insertion end of a fork pocket open even in a case where the pallet situates between upper and lower cargoes.

[0016] A further object of this invention is to provide a flexible pallet capable of easily inserting forks of a forklift into fork pockets even in a case where a heavy load cargo is placed on a pallet main body.

[0017] A further object of this invention is to provide a flexible pallet capable of further facilitating the insertion of forks into fork pockets.

[0018] A further object of this invention is to provide a flexible pallet capable of easily inserting forks of a forklift into fork pockets even in a case where the load of a cargo on the pallet exerts as far as the edge of the pallet main body.

[0019] A further object of this invention is to provide a flexible pallet free from the disadvantage that forks of a forklift cannot be inserted into fork pockets because of creasing of fork pocket members in a state where a cargo is not located on a pallet main body.

[0020] A further object of this invention is to provide a flexible pallet free from the disadvantage that a pallet main body does not detach from forks even in a case where a flowable cargo such as resin is located on the pallet main body.

[0021] A further object of this invention is to provide a flexible pallet capable of reducing the resistance between a fork pocket members and forks thereby capable of inserting the forks into the fork pockets smoothly even in a case where a cargo such as a rice no more having flowability when packed is located on a pallet main body.

[0022] A further object of this invention is to provide a flexible pallet with no disadvantage that a pallet main body is moved and forks cannot be inserted, and with no worry that a cargo located on the pallet main body should fall even when the forks are inclined somewhat, even in a case where the forks of a forklift are inserted into fork pockets in a state not containing a cargo located on the pallet main body.

[0023] A further object of this invention is to provide a flexible pallet capable of making the lower surface of a pallet main body into a flat surface and capable of facilitating insertion of forks into fork pockets.

[0024] A still further object of this invention is to provide a flexible pallet capable of being used as a rigid pallet in a case of a so-called “packaged freight” which causes unevenness at the bottom, formed by integrating plural small-sized cargoes into one large cargo and placing the same on one identical pallet, as well as capable of greatly reducing the height of the pallet.

DISCLOSURE OF THE INVENTION

[0025] This invention comprises a flexible pallet comprising a soft pallet main body at least having an upper surface member; and a soft fork pocket member disposed to the lower surface of the upper surface member and forming substantially cylindrical fork pockets in a state attached to the pallet main body.

[0026] By manufacturing the pallet main body and the fork pocket member with a soft material, manufacture is facilitated and production at a reduced cost is possible and it can be folded into a reduced volume during transportation or storage. Further, it is possible to decrease the amount of wastes to be discarded after use.

[0027] Further, this invention is characterized in the pallet main body has an elongate reinforcing member of a higher rigidity than the pallet main body at the end edge on the insertion side of the fork pocket.

[0028] Then, the distance between the fork pockets on both sides is kept substantially constant even when it is applied as a pallet for a cargo at a second or higher stage loaded on a cargo, which is free from the disadvantage that forks cannot be inserted into the fork pocket.

[0029] Further, this invention is characterized in that an elongate reinforcing member situates outward of a cargo located on the pallet main body.

[0030] With the constitution, the weight of a cargo is loaded on the portion of the elongate reinforcing member to avoid the disadvantage that the forks cannot be inserted easily into the fork pockets.

[0031] Further, this invention is characterized in that an elongate reinforcing member situates outward of a cargo located on the pallet main body.

[0032] Then, even in a case where a heavy cargo weight with no flat bottom is located on the pallet main body, load exerting on the fork pocket is averaged making it possible to smoothly inserting the forks of a forklift into fork pockets.

[0033] Further, this invention is characterized in that the upper surface member has an insertion end reinforcing member bent convexly upward at the end on the insertion side of the fork pocket.

[0034] This can always keep the end of the fork pocket on the insertion side open and allows insertion of the forks of a forklift into the fork pockets.

[0035] Further, this invention is characterized in that an insertion end reinforcing member situates outward of a cargo located on the pallet main body.

[0036] This can avoid the disadvantage that the open end of the insertion side of the fork pocket is closed to hinder the insertion of forks even in a case where a heavy weight cargo is located on the pallet main body.

[0037] Further, this invention is characterized in that the upper surface member has tongues each protruding outward of the cargo on the pallet main body at a portion corresponding to the insertion end of the fork pocket.

[0038] This allows the tongue to protrude always outward of the cargo even in a case where a pallet situates between upper and lower cargoes to enable easy visual recognition for the position of the fork pocket.

[0039] This invention further characterized in that the tongue is applied with a rigidity increasing treatment.

[0040] This allow easy insertion of forks of a forklift into fork pockets even in a case where a pallet situates between upper and lower cargoes.

[0041] This invention further characterized in that the tongue is pulled upward along the outer surface of the cargo located on the pallet main body.

[0042] This can keep the insertion end of the fork pocket to flare vertically even in a case where the pallet situates between upper and lower cargoes. Further, when the tongue pulled upward is fixed to the cargo, the pallet and the cargo are integrated thereby enabling to improve the stability of the cargo.

[0043] Further, this invention is characterized in that the fork pocket member is cut to separate at the lower surface of the insertion top end thereof from the upper surface member.

[0044] This facilitates vertical flaring of the insertion top end of the fork pocket members thereby allowing easy insertion of the forks of the forklift into the fork pockets.

[0045] This invention further characterized in that the portion of the fork pocket member cut to separate from the upper surface member is applied with a rigidity increasing treatment.

[0046] This can prevent the portion cut to separate from the upper surface material of the fork pocket member from being rolled together with the fork into the fork pocket and allows easier insertion of the forks when the forks of the forklift are inserted into the fork pocket members.

[0047] Further, this invention is characterized in that the portion of the fork pocket member cut to separate from the upper surface member protrudes outward of the outer edge of the pallet main body.

[0048] This allows easy insertion of the forks of the forklift into the fork pockets even in a case where the load of a cargo on the pallet exerts as far as the edge of the pallet main body.

[0049] This invention further characterized in that at least the upper portion on the inner surface of the fork pocket member is formed of a woven fabric made of plastic filaments.

[0050] This makes the upper portion on the inner surface of the fork pocket member into a slippy surface having a predetermined rigidity and can avoid the disadvantage that the fork pocket member is creased and the forks cannot be inserted even in a case where the forks of the forklift are inserted into the fork pockets in a state where a cargo in not located on the pallet main body.

[0051] This invention further characterized in that the woven fabric is formed of plastic filaments in which the warps extending in the fork insertion direction have a smaller diameter and the wefts have a larger diameter.

[0052] This can avoid the disadvantage that the pallet main body detaches from the forks even in a case where a cargo such as a resin having a flowability is located on the pallet main body.

[0053] Further, this invention is characterized in that the woven fabric is formed of plastic filaments in which the warps extending in the form insertion direction have a larger diameter and the wefts have a smaller diameter.

[0054] This can reduce the resistance between the fork pocket member and the fork and allows smooth insertion of the forks into the fork pockets even in a case where a cargo such as rice no more having flowability when packed is located on the pallet main body.

[0055] This invention is further characterized in that the grounding surface and the surface in contact with a cargo of the pallet main body is applied with a less slippy treatment.

[0056] This can avoid the disadvantage that the pallet main body moves and fork cannot be inserted in a case where the forks of the forklift are inserted into the fork pockets, as well as there is no worry that a cargo located on the pallet main body should fall even when the forks are inclined slightly.

[0057] This invention is further characterized in that the pallet main body comprise an upper surface member; and a lower surface member disposed to the lower surface of the upper surface member and having substantially identical shape and size with those of the upper surface member in which the fork pocket is formed between the upper surface member and the lower surface member, and the end edge of the lower surface member on the insertion side of the fork pocket protrudes outward of the upper surface member.

[0058] This can make the lower surface of a pallet main body into a flat surface and allows easy insertion of forks into the fork pocket.

[0059] This invention is further characterized in that the pallet main body comprise an upper surface member; and a lower surface member disposed to the lower surface of the upper surface member and having substantially identical shape and size with the upper surface member in which the fork pocket is disposed to the lower surface of the lower surface member, and at least one of four sides of the upper surface member and the lower surface member is made openable, such that a pallet main body reinforcing pallet can be inserted between both of the surface members.

[0060] This enables to use the pallet as a rigid pallet in a case of a cargo causing unevenness at the bottom as in a so-called ‘packaged freight’ described above and enables to reduce the height of the pallet greatly.

BRIEF DESCRIPTION OF THE DRAWINGS

[0061]FIG. 1 is a plan view showing a flexible pallet according to a first embodiment of this invention.

[0062]FIG. 2 is a bottom view of the embodiment shown in FIG. 1.

[0063]FIG. 3 is a cross sectional view taken along line III-III in FIG. 1.

[0064]FIG. 4 is a cross sectional view taken along line IV-IV in FIG. 1;

[0065]FIG. 5 is an explanatory view showing a manufacturing method for an upper surface member.

[0066]FIG. 6 is a cross sectional view taken along line VI-VI in FIG. 5.

[0067]FIG. 7 is an explanatory view showing a manufacturing method for a lower surface material.

[0068]FIG. 8 is a cross sectional view taken along line VIII-VIII in FIG. 7.

[0069]FIG. 9 is an explanatory view showing a state of providing an outer slit and an inner slit to the lower surface member.

[0070]FIG. 10 is an explanatory view showing a state in which an upper surface member and a lower surface member are stitched to each other.

[0071]FIG. 11 is an explanatory view of a completed flexible pallet as viewed from the lower surface member.

[0072]FIG. 12 is a view corresponding to FIG. 1 showing a second embodiment of this invention.

[0073]FIG. 13 is a view corresponding to FIG. 1 showing a third embodiment of this invention.

[0074]FIG. 14 is a cross sectional view taken along line XIV-XIV.

[0075]FIG. 15 is an explanatory view showing the shape of an insertion end reinforcing material.

[0076]FIG. 16 is a view corresponding to FIG. 1 showing a fourth embodiment of this invention.

[0077]FIG. 17 is a cross sectional view taken along line XVII-XVII in FIG. 16.

[0078]FIG. 18 is a view corresponding to FIG. 1 showing a fifth embodiment according to this invention;

[0079]FIG. 19 is a cross sectional view taken along line XIX-XIX in FIG. 18.

[0080]FIG. 20 is a view corresponding to FIG. 1 showing a sixth embodiment according to this invention.

[0081]FIG. 21 is a view corresponding to FIG. 1 showing a seventh embodiment according to this invention.

[0082]FIG. 22 is a constitutional view of FIG. 21 as viewed from the side;

[0083]FIG. 23 is a cross sectional view taken along line XXIII-XXIII in FIG. 22.

BEST MODE FOR PRACTICING THE INVENTION

[0084] This invention is to be explained with reference to the drawings.

[0085]FIG. 1 to FIG. 4 show a flexible pallet as a first embodiment according to this invention. A flexible pallet 1 comprises a soft pallet main body 2 having an upper surface member 3 formed of a plastic film or a flat yarn woven fabric such as made of PE, PP and PET. A lower surface member 4 made of the same material and of the same size as those of the upper surface member is stitched to the lower surface of the pallet main body 2. Then, fork pockets 5 each of a substantially cylindrical shape for inserting forks of a fork lift not illustrated are formed at two positions between the upper surface member 3 and the lower surface member 4. The inner surface members 6 and 7 are attached to the lower surface of the upper surface member 3 and the upper surface of the lower surface member 4, respectively, corresponding to each of the fork pockets 5 as shown in FIG. 3 and FIG. 4, which provide the fork pockets 5 with an appropriate rigidity and ensure an appropriate slidability relative to the forks of the fork lift.

[0086] Each of the inner surface members 6 and 7 is formed, for example, of a woven fabric of PP monofilaments and the fineness of the filament is selected between 400 d (denier) and 2000 d. Warps extending in the insertion direction of the fork and weft perpendicular thereto are made of filaments of diameters different from each other.

[0087] That is, in a case where the diameter of the warp is made smaller and that of the weft is made larger, resistance between the folks of the forklift and the woven fabric increases somewhat. Accordingly, in a case where a cargo such as a resin having a flowability is transported, detaching of the flexible pallet 1 from the forks can be prevented effectively by using the warps of smaller diameter and the wefts of larger diameter.

[0088] On the other hand, in a case where the diameter of the warp is made larger and that of the weft is made smaller, the resistance between the woven fabric and the forks of the forklift decreases somewhat. Accordingly, in a case where a cargo such as a resin no more having flowability when packed, is transported by the flexible pallet 1, the forks can be smoothly inserted into the fork pockets by the woven fabric having warps of larger diameter and the wefts of smaller diameter to avoid the disadvantage that the forks are caught and can not be inserted.

[0089] As shown in FIG. 2, an outer slit 8 and an inner slit 9 are formed on both sides of the lower surface member 4 corresponding to both ends of the fork pocket 5 respectively, which separate the fork pocket end 10 from the upper surface member 3 and can easily insert the fork of the forklift into the fork pocket 5. Further, a portion 11 put between the inner slits 9 on both sides is turned back toward the lower surface of the lower surface member 4 and joined in a 2-layered stack.

[0090] A ring-like rope passing member 12 is attached to a position above each of the fork pocket ends 10, that is, to the lower surface at the end of the inner surface member 6 as shown in FIG. 2 and FIG. 4. Further, rope passing members 13 are attached to both side edges of the flexible pallet 1 perpendicular thereto in a state being put between the upper surface member and the lower surface member 4 by the number of four in total as shown in FIG. 1 to FIG. 3.

[0091] Each of the rope passing members 12, 13 is used for binding to integrate the flexible pallet 1 and a cargo loaded thereon by means of ropes. Since the rope passing member 12 is attached to the end of each fork pocket 5, the end of the upper surface member 3 substantially protrudes outward of the outer edge of the flexible pallet 1 to allow easier insertion of the forks into the fork pocket 5.

[0092] Next, a method of manufacturing the flexible pallet is to be described.

[0093] Upon manufacture, as shown in FIG. 5, the inner surface member 6 is at first stitched to the lower surface of the upper surface member 3 at two positions. Then, as shown in FIG. 6, both extension ends of the lower surface member 4 extended in the direction of the inner surface members 7 are wrapped with band-like edge wrapping members 14 and stitched as shown in FIG. 6, and the rope passing members 12 are stitched to the lower surface of the inner surface member 6. This increases the rigidity of both end edges of the fork pocket 5, so that the upper surface member 3 is not rolled into the fork pocket 5 upon insertion of the fork into the fork pocket 5.

[0094] Then, as shown in FIG. 7, the inner surface member 7 is stitched to the upper surface of the lower surface member 4 at two positions and then, as shown in FIG. 8, both ends of the lower surface member 4 in the extending direction of the inner surface member 7 are wrapped and stitched with band-like edge wrapping members 15. Stitching by the edge wrapping members 15 increases the rigidity on both end edges of the fork pocket 5, so that the lower surface member 4 is not rolled into the fork pocket upon insertion of the forks into the fork pockets 5.

[0095] Then, as shown in FIG. 9, outer slits 8 and inner slits 9 are formed, respectively, on both sides of each rope passing member 12 of the lower surface member 4, for example, by heat cutting. Thus, the fork pocket ends 10 and portions 11 each put between them are formed, respectively. The sandwiched portion 11 is then turned back on and stitched to the lower surface of the lower surface member 4.

[0096] Then, as shown in FIG. 10, the upper surface member 3 and the lower surface member 4 are formed as dual layered stack into which the rope passing member 13 is interposed therebetween and the upper surface member 3 and the lower surface member 4 are stitched to each other in this state. Thus, fork pockets 5 are formed between both of the surface members 3 and 4.

[0097] Finally, both lateral end edges of the surface members 3 and 4 shown in FIG. 10 are wrapped with bound-like outer edge members 16 each having an aperture 17 at a position corresponding to the rope passing member 13 to complete the flexible pallet 1 shown in FIG. 11.

[0098] Then, since the flexible pallet 1 can be manufactured entirely with the plastic material, manufacture is easy and the pallet can be manufactured at a reduced cost and the amount of wastes to be discarded after use can also be reduced. Further, the pallet can be folded into a reduced volume during transpiration or storage, and is quite free from the worry of deformation or the reduction of the strength even when wetted with rainfall or the like.

[0099] In the first embodiment, it has been explained that each of the inner surface members 6, 7 is formed of the woven fabric made of pp monofilaments. However, in a case where it is necessary to improve the slidability further relative to the forks of the forklift, each of the inner surface members 6, 7 may be formed preferably of a woven fabric made of PE monofilaments.

[0100]FIG. 12 shows a second embodiment according to this invention in which elongate reinforcing members 20 are added to the constitution of the flexible pallet 1 in the first embodiment.

[0101] That is, as shown in FIG. 12, elongate reinforcing members 20 are disposed on both end edges at the upper surface of the upper surface member 3 on the insertion side of the fork pockets 5 substantially over the entire length for the lateral size of the upper surface member 3 respectively. Each of the reinforcing members 20 is made of a material having a higher rigidity that that of the upper surface member 3, such as a rod, tube or plate member made of plastic, wood, metal or rubber, or a crumpled or folded plastic sheet. Each of the reinforcing members 20 is attached fixedly or detachably at a position outward of a cargo 21 located on the upper surface member 3. Each of the reinforcing members 20 is adapted to maintain the flatness of the flexible pallet in order for avoiding the disadvantage that the distance between the fork pocket 5 on both sides is narrowed to inhibit insertion of the forks of the forklift into the fork pockets 5 or the disadvantage that the positions for the fork pockets 5 on the right and left are displaced vertically making it difficult for the insertion of the forks in the fork pockets.

[0102] Other constitutions and the functions are identical with those of the first embodiment described above.

[0103] Then, since the reinforcing members 20 are disposed on both end edges at the upper surface of the upper surface member 3 on the insertion side of the fork pockets 5, also in a case where the flexible pallet 1 is used as a pallet for a cargo 21 at a second or higher stage loaded on the cargo 21, the distance between the fork pockets 5 on both sides can be maintained substantially constant to be free of the disadvantage that the forks can not be inserted into the fork pockets 5. In addition, there is no worry that the positions for the fork pockets 5 on the right and left are displaced vertically. Further, since each of the reinforcing members 20 is situated outward of the cargo 21, there is no worry that the weight of the cargo 21 is localized to a portion of the reinforcing member 20 to inhibit insertion of the forks.

[0104] In the second embodiment, while descriptions have been made to a case of disposing two reinforcing members, the intended effect will be attained by disposing one reinforcing member 20 only at the end on the fork insertion side in a case where the inserting direction of the forks is predetermined.

[0105]FIG. 13 to FIG. 15 show a third embodiment according to this invention in which insertion end reinforcing members 30 and extension members 31 are added to the constitution of the flexible pallet 1 of the first embodiment.

[0106] That is, as shown in FIG. 13 and FIG. 14, insertion end reinforcing members 30 such as formed of plastic ropes are disposed by the number of four in total on both ends at the upper surface member 3 on the insertion side of the fork pockets 5. Each of the insertion end reinforcing members 30 is secured to the upper surface member 3, for example, by being wrapped and stitched with the upper surface member 3 and convexly bent upward as shown in FIG. 15. Thus, this can keep the end of the fork pocket 5 always open or flared.

[0107] Each of the insertion end reinforcing members 30 is disposed at a position outward of the cargo 21 located on the upper surface member 3 like the reinforcing member 20 in the second embodiment, which prevents the end of the fork pocket 5 in the open state from being crashed by the weight of the cargo 21.

[0108] On the other hand, as shown in FIG. 13 and FIG. 14, an extension member 31 protruding outward of the end edge of the upper surface member 3 is disposed integrally on both end edges on the insertion side of the fork pocket 5 in the lower surface member 4 by extending the lower surface member 4. Each of the extension members 31 is applied with a rigidity increasing treatment by integrally stitching a plastic sheet or like other rigidity increasing member 32.

[0109] Each of the extension members 31 is disposed for easy insertion of the forks of the forklift into the fork pockets 5. However, it has been confirmed by the experiment made by the present inventors that the insertion of the forks is rather difficult when the length of the member is unnecessarily long, and an appropriate length is about 5 to 15 cm.

[0110] As shown in FIG. 14, less sliding sheets 33, 34 such as made of an EVA sheet or rubber sheet are disposed integrally by means of lamination, sizing or stitching to the upper surface of the upper surface member 3 and the lower surface of the lower surface member 4. Then, the less slippy sheet 33 of the upper surface member 3 can prevent falling of the cargo 21 from the place on the pallet main body 2, as well as the less slippy sheet 34 of the lower surface member 4 can avoid the disadvantage that the flexible pallet 1 slips and the forks can not be inserted into the fork pockets 5 upon insertion of the forks of the forklift into the fork pockets 5 in a state where the cargo 21 is not present on the pallet main body 2.

[0111] Other constitutions and the functions are identical with those in the first embodiment.

[0112] Then, provision of the insertion reinforcing members 30 can keep the ends fork pockets 5 always open and extremely facilitate the insertion of the forks of the forklift. Further, since the lower surface member 4 has the extension member 31 applied with the rigidity increasing treatment, the forks can be inserted more easily into the fork pockets 5.

[0113] In the third embodiment described above, description has been made to a case in which the insertion end reinforcing members 30 are disposed on both ends of the fork pockets 5 and the extension members 31 are also disposed on both end edges, respectively, but the intended effect can be obtained by disposing the reinforcing member only at the end of the insertion side in a case where the fork insertion direction is predetermined.

[0114]FIG. 16 and FIG. 17 show a fourth embodiment according to this invention in which tongues 40 are disposed instead of the insertion end reinforcing members 30 in the third embodiment.

[0115] That is, as shown in FIG. 16 and FIG. 17, tongues 40 each producing outward of the cargo 21 located on the pallet main body 2 are disposed integrally by extending the upper surface member 3 at the end positions for the insertion of the fork pocket 5 in the upper surface member 3. The protruding length is set to a length substantially identical with that of the extension member 31 of the lower surface member. Then, each of the tongues 40 is applied with a rigidity increasing treatment by integrally stitching a plastic sheet or like other rigidity increasing member 42.

[0116] Other constitutions and functions are identical with those of the third embodiment.

[0117] Since the tongues 40 disposed to the upper surface member 3 protrude outward of the cargo 21 on the pallet main body 2, the position for the fork pockets 5 can easily be recognized visually even in a case where the flexible pallet 1 is located between upper and lower cargoes 21. In addition, since the tongue 40 is applied with the rigidity increasing treatment, the tongue is not rolled into the fork pocket 5 upon insertion of the forks into the fork pockets 5 and the forks can be inserted easily.

[0118]FIG. 18 and FIG. 19 shows a fifth embodiment according to this invention, in which tongues 50 and binding strings 51 are used instead of the tongues 40 in the forth embodiment.

[0119] As show in FIG. 18 and FIG. 19, tongues 50 each protruding outward of a cargo 21 on a pallet main body 2 are disposed integrally with an upper surface member 3, and each binding string 51 is attached to the protruding top end of the tongue 50. As shown in FIG. 19, each of the tongues 50 is pulled upward along the outer surface of the cargo 21 and connected by way of the string 51 to the cargo 21, or binding strings 51 are bound to each other on the outer surface of the cargo 21.

[0120] Other constitutions and the functions are identical with those of the fourth embodiment.

[0121] Since the tongues 50 are pulled upward along the outer surface of the cargo 21, the position for the fork pockets 5 can easily be recognized easily and since each of the ends of the fork pockets 5 is opened by pulling each tongues 50 upward, the forks can be inserted easily as well.

[0122]FIG. 20 shows a sixth embodiment according to this invention in which band-like fork pocket reinforcing members 60 are added to the constitution of the flexible pad 1 of the first embodiment.

[0123] As shown in FIG. 20, band-like fork pocket reinforcing members 60 are disposed over the entire length of the fork pocket 5 at positions corresponding to fork pockets 5 on the right and left at the upper surface of an upper surface member 3 respectively. Each of the fork pocket reinforcing members 60 is constituted with a plate member having higher rigidity than the upper surface member 3 such as a plastic plate, board plate, corrugated board or ply wood plate, and each of the fork pocket reinforcing members 60 is secured integrally to the upper surface member 3. Since the upper surface of the fork pockets 5 is reinforced by each of the fork pocket reinforcing members 60, even when a heavy weight cargo with no flattened bottom is located on the flexible pallet, the load exerting on the fork pockets 5 is averaged and the forks of the forklift can be inserted smoothly into the fork pockets 5.

[0124] Other constitutions and functions are identical with those of the first embodiment.

[0125] Since the upper surface of each of the fork pockets 5 is reinforced with the fork pocket reinforcing member 60, even when a heavy load is localized on the fork pockets 5, the load is averaged by the fork pocket reinforcing members 60 and, accordingly, the forks of the forklift can be inserted smoothly into the fork pockets 5.

[0126]FIG. 21 to FIG. 23 show a seventh embodiment according to this invention in which a flexible pallet 1 is adapted to be usable also as a rigid pallet. As show in FIG. 21 to FIG. 23, a flexible pallet 1 according to this embodiment comprises a pallet main body 2 having an upper surface member 3 and a lower surface member 4, in which both of the surface members 3 and 4 are joined by stitching only on two opposing sides by a stitching portion 70 into a cylindrical shape. Between both of the surface members 3 and 4, is inserted and disposed a pallet main body reinforcing plate 71 having a predetermined rigidity such as a plywood plate, corrugated board, board paper, rigid plastic plate or metal plate such that the plate can be inserted and detached. This makes the soft pallet main body 2 rigid and allows the flexible pallet 1 to be used as a rigid pallet.

[0127] Further, as shown in FIG. 21 to 23, cylindrical fork pocket members 72 are attached, respectively, to the lower surface of the lower surface ember 4, so that fork pockets 5 are formed with the fork pockets members 72.

[0128] Other constitutions and functions are identical with those of the first embodiment.

[0129] Since the flexible pallet 1 can be used also as the rigid pallet, a cargo having unevenness at the bottom such as a so-called “packaged freight” described above or plural small-sized cargoes located together with no integration on the pallet main body can also be transported with no troubles. In addition, the height of the pallet can be lowered remarkably also in this case compared with existent rigid pallets and the loading efficiency can be improved to decrease the transportation cost.

[0130] In the seventh embodiment, while the description has been made to a case of forming the fork pocket 5 with the cylindrical fork pocket member 72, a band-like fork pocket member may be attached to the lower surface of the lower surface member 4 to form the fork pocket 5.

[0131] Further, in each of the embodiments described previously, description has been made to a case of disposing the inner surface members 6 and 7 on both upper surface and the lower surface of the fork pockets 5, the intended effect can be expected providing that the inner surface member 6 is present at least on the side of the upper surface.

[0132] Further, in each of the embodiments described previously, while description has been made to a case of forming the inner surface members 6 and 7 with woven fabrics made of monofilaments, they may be also made of plastic films.

[0133] In a case of using the plastic film, it has been confirmed by the experiment of the present inventors that the sliding friction coefficient of the film is within a range shown in Table 1 and the strength thereof is preferably within the range of values shown in Table 2. TABLE 1 Dynamic friction Sliding angle-converted coefficient value min. 0.10  5.7° max. 0.18 10.2°

[0134] TABLE 2 Piercing strength (N) Tear strength (N) Vertical 39 or more 200 or more Horizontal 28 or more 170 or more

[0135] As has been described above, in accordance with this invention, since the flexible pallet comprises a soft pallet main body having at least an upper surface member; and a soft fork pocket member disposed to the lower surface of the upper surface member and forming a substantially cylindrical fork pocket in a state attached to the pallet main body, manufacture is easy and the pallet can be manufactured at a reduced cost by manufacturing the pallet main body and the fork pocket member with a soft material, as well as the pallet can be folded into a reduced volume upon transportation or storage. Further, the amount of wastes to be discarded after use can be decreased.

[0136] Further, in accordance with this invention, since the elongate reinforcing member of a higher rigidity than the pallet main body is disposed to the end edge of the pallet main body on the insertion side of the fork pocket, even when it is applied as the pallet for a cargo at a second or higher stage loaded on the cargo, a distance between fork pockets on both sides can be maintained substantially constant to avoid the disadvantage that forks can not be inserted to the fork pockets.

[0137] Further, in accordance with this invention, since the elongate reinforce member is disposed outward of the cargo on the pallet main body, it can avoid the disadvantage that the weight of the cargo is loaded on the portion of the elongate reinforcing member to make the insertion of the forks into the fork pockets difficult.

[0138] Further in accordance with this invention, since band-like fork pocket reinforcing members of a higher rigidity than the pallet main body are disposed each to a position corresponding to a portion above the fork pocket in the pallet main body, even in a case where a heavy weight cargo with no flat bottom is located on the pallet main body, load exerting on the fork pockets is averaged and the forks of the forklift can be inserted smoothly into the fork pockets.

[0139] Further, in accordance with this invention, since the insertion end reinforcing members convexly bend upward are disposed each to the end of the upper surface member on the insertion side of the fork pocket, the end on the insertion side of the fork pocket can be always kept open thereby easy insertion of the forks of the forklift into the fork pockets.

[0140] Further, in accordance with this invention, since the insertion end reinforcing members are situated outward of the cargo located on the pallet main body, even in a case where a heavy weight cargo is located on the pallet main body, there is no worry that the open ends on the insertion side of the fork pockets are closed to hinder the insertion of the forks.

[0141] Furthermore, in accordance with this invention, since tongues protruding outward of the cargo on the pallet main body are disposed each at a position corresponding to the upper surface member on the insertion end of the fork pocket, even in a case where the pallet is situated between the upper and lower cargoes, the tongues always protrude out of the cargo, and the position for the fork pocket can easily be recognized visually.

[0142] Further, in accordance with this invention, since the tongues are applied with the rigidity increasing treatment, even in a case where the pallet is situated between the upper and lower cargoes, forks of the forklift can be inserted easily into the fork pockets.

[0143] Further, in accordance with this invention, since the tongues are pulled upward along the outer surface of the cargo on the pallet main body, the tongues always protrude out of the cargo even in a case where the pallet is situated between the upper and lower cargoes, the positions for the fork pockets can be easily recognized.

[0144] Further, in accordance with this invention, since the tongues are applied with the rigidity increasing treatment, even in a case where the pallet is situated between upper and lower cargoes, the forks of the forklift can be inserted easily into the fork pockets.

[0145] Further, in accordance with this invention, since the tongues are pulled upward along the outer surface of the cargo located on the pallet main body, even in a case where the pallet is situated between upper and lower cargoes, the insertion ends of the fork pockets can be kept open vertically. Further, when the tongues pulled up are secured to the cargo, the pallet and the cargo can be integrated to improve the stability of the cargo.

[0146] Further, in accordance with this invention, since the lower surface of the insertion top ends of the fork pocket members is cut to separate from the upper surface member, the insertion top ends of the fork pocket members can be easily opened vertically, and the forks of the forklift can be inserted easily into the fork pockets.

[0147] Further, in accordance with this invention, since the portions cut to separate from the upper surface member of the fork pocket members are applied with the rigidity increasing treatment, when the forks of the forklift are inserted into the fork pocket members, the portion separated from the upper surface material of the fork pocket member are no more rolled into the fork pocket together with the forks to further facilitate the insertion of the forks.

[0148] Further, in accordance with this invention, since the portions cut to separate from the fork pocket members on the side of the upper surface member protrude outward of the outer edges of the pallet main body, even in a case where the weight of the cargo located on the pallet is loaded as far as the edges of the pallet main body, the forks of the forklift can be inserted easily into the fork pockets.

[0149] Further, in accordance with this invention, since at least the upper portion on the inner surface of the fork pocket member is formed of a woven fabric made of plastic filaments, the upper portion on the inner surface of the filament pocket member forms a slippy surface having a predetermined rigidity and, even in a case where the forks of the forklift are inserted into the fork pockets in a state in which a cargo is not loaded on the pallet main body, there is no worry that the fork pocket member is creased and the fork can not be inserted.

[0150] Further, in accordance with this invention, since the woven fabric is made of plastic filaments in which the warps extending in the fork insertion direction of the forks have a smaller diameter, while the wefts have a larger diameter, even in a case where a cargo such as a resin having flowability is loaded on the pallet main body, there is no worry that the pallet main body detaches from the forks.

[0151] Further in accordance with this invention, since the woven fabric is made of plastic filaments in which the warps extending in the insertion direction of the fork have a larger diameter, while the wefts have a larger diameter, even in a case where a cargo such as rise having flowability no more when packed is located on the pallet main body, the resistance between the fork pocket member and the fork is reduced to allow smooth insertion of the forks into the fork pockets.

[0152] Further, in accordance with this invention, since the less slippy treatment is applied to the grounding surface and to the surface in contact with the cargo of the pallet main body, even in a case where the forks of the forklift are inserted into the fork pockets in a state in which a cargo is not located on the pallet main body, there is no worry that the pallet main body moves and the forks can not be inserted, as well as there is no worry that the cargo falls from the pallet main body even when the forks are inclined somewhat.

[0153] Further, in accordance with this invention, since the pallet main body comprises the upper surface member; and the lower surface member disposed to the lower surface of the upper surface member and having substantially the same shape and size with those of the upper surface member; the fork pockets are formed between the upper surface member and the lower surface member and the end edges of the lower surface member on the insertion side of the fork pockets protrude outward of the upper surface member, the lower surface of the pallet main body can be made into a flat surface and insertion of the forks into the fork pockets can be facilitated.

[0154] Furthermore, in accordance with this invention, since the pallet main body comprises the upper surface member; and the lower surface member disposed on the lower surface of the upper surface member and having substantially identical shape and size with those of the upper surface member, the fork pocket member is disposed to the lower surface of the lower surface member, and at least one of four sides of the upper surface member and the lower surface member is made openable and the pallet main body reinforcing member can be inserted between both of surface members, it can be used as a rigid pallet in a case of a cargo causing unevenness at the bottom such as a so-called “packaged freight”. In addition, the height of the pallet can be decreased remarkably also in this case.

[0155] Industrial Applicability

[0156] As has been described above, the flexible pallet according to this invention can be folded into a reduced volume upon transportation or storage, which is useful as a flexible pallet with less amount of wastes to be discarded after use and it is, particularly, suitable to a flexible pallet capable of easily inserting the forks of the forklift into the fork pockets. 

1. A flexible pallet comprising a soft pallet main body at least having an upper surface member; and a soft fork pocket member disposed to the lower surface of the upper surface member and forming substantially cylindrical fork pockets in a state attached to the pallet main body, in which the pallet main body has an elongate reinforcing member of a higher rigidity than the pallet main body at the end edge on the insertion side of the fork pocket:
 2. (deleted)
 3. A flexible pallet as defined in claim 1, wherein an elongate reinforcing member situates outward of a cargo located on the pallet main body.
 4. A flexible pallet as defined in claim 1 or 3, wherein the elongate reinforcing member is provided only at a portion corresponding to a position above the fork pocket.
 5. A flexible pallet comprising a soft pallet main body at least having an upper surface member; and a soft fork pocket member disposed to the lower surface of the upper surface member and forming substantially cylindrical fork pockets in a state attached to the pallet main body, in which the upper surface member has an insertion end reinforcing member bent convexly upward at the end on the insertion side of the fork pocket.
 6. A flexible pallet as defined in claim 5, wherein the insertion end reinforcing member situates outward of a cargo located on the pallet main body.
 7. A flexible pallet comprising a soft pallet main body at least having an upper surface member; and a soft fork pocket member disposed to the lower surface of the upper surface member and forming substantially cylindrical fork pockets in a state attached to the pallet main body, in which the upper surface member has tongues each protruding outward of the cargo on the pallet main body at a portion corresponding to the insertion end of the fork pocket, and the tongue is pulled upward along the outer surface of the cargo located on the pallet main body.
 8. (deleted)
 9. (deleted)
 10. (deleted)
 11. (deleted)
 12. (deleted)
 13. A flexible pallet as defined in claims 1, 3, 5, 6 or 7, wherein at least the upper portion of the inner surface of the fork pocket member is formed of a woven fabric made of plastic filaments.
 14. A flexible pallet as defined in claim 13, wherein the woven fabric is formed of plastic filaments in which warps extending in the fork insertion direction have a smaller diameter and wefts have a larger diameter.
 15. A flexible pallet as defined in claim 13, wherein the woven fabric is formed of plastic filaments in which warps extending in the form insertion direction have a larger diameter and wefts have a smaller diameter.
 16. A flexible pallet as defined in claim 1, 5 or 7, wherein the grounding surface and the surface in contact with a cargo of the pallet main body is applied with a less slippy treatment.
 17. A flexible pallet as defined in claim 1, 5 or 7, wherein the pallet main body comprise an upper surface member; and a lower surface member disposed to the lower surface of the upper surface member and having substantially identical shape and size with those of the upper surface member in which the fork pocket is formed between the upper surface member and the lower surface member.
 18. A flexible pallet comprising a soft pallet main body at least having an upper surface member; and a soft fork pocket member disposed to the lower surface of the upper surface member and forming substantially cylindrical fork pockets in a state attached to the pallet main body, in which the pallet main body comprise an upper surface member; and a lower surface member disposed to the lower surface of the upper surface member and having substantially identical shape and size with those of the upper surface member in which the fork pocket is disposed to the lower surface of the lower surface member, and at least one of four sides of the upper surface member and the lower surface member is made openable, such that a pallet main body reinforcing plate can be inserted between both of the surface members. 